Sprayed in place pipe lining apparatus and method thereof

ABSTRACT

A method and apparatus for applying a liner to a pipe is disclosed. The apparatus includes a base assembly having a plurality of guide rails and a shuttle plate attached thereto. The apparatus also includes a motor module attached to an end of the base assembly. An extension arm is connected to a top surface of the shuttle plate. The extension arm has a spray head assembly attached at an opposite end thereof. The extension arm and spray head assembly will move relative to the base assembly of the apparatus. A fast cure coating will be applied via the spray head assembly to the interior surface of a pipe being rehabilitated. The spray head assembly will have an air blow off mechanism therein thus allowing for the tip of the spray head assembly to stay relatively clog free during the fast cure coating operation of the apparatus. The methodology also includes an oscillation system wherein the spray head assembly will move relative to the base assembly thus creating an over lapping pattern for the spray coating being applied to the interior surface of the pipeline. This oscillation system will allow for a more uniform coating to be applied.

FIELD OF THE INVENTION

[0001] The present invention generally relates to apparatuses andmethods for coating the interior surface of a pipeline and moreparticularly relates to spraying a coating to form a liner within apipeline environment.

DESCRIPTION OF RELATED ART

[0002] It is well known in the prior art to recondition the interior ofpipes within existing or new sewer or another type of under ground pipesystems by any of the known prior art methods and apparatuses. Many ofthe under ground pipelines maybe corroded, have other problems thatrequire fixing or total replacement or may be a new pipe section thatrequires a liner. Total replacement of these pipelines is very oftenboth economically and practically not feasible because of downtime ofthe pipeline and the costs involved in excavating and laying newpipelines. Hence, this prior art method of locating the most seriouslydeteriorated sections of a pipeline and then excavating such section ofpipe and patching or replacing that section with new pipe, is veryexpensive and time consuming and only delays the inevitabledeterioration of the rest of the pipeline and frustrates users andowners of the pipeline system because of the on going work needed tokeep the systems operating.

[0003] There also are many known insitu form processes for cured inplace pipe liners in the prior art. This is the most commonly used formof repairing deteriorated pipes in the prior art. One such method ofinsitu fixing of deteriorated pipelines includes pulling a flexiblepolyethylene liner pipe into and through the deteriorated concrete ormetal pipeline area to form a continuous corrosion barrier. This pulledin liner pipe is then set to the interior surface of the pipeline beingfixed. This setting is accomplished by curing the polyethylene liner tothe pipe's internal surface.

[0004] Still another prior art insitu pipeline repair method includesthe pulling through of deteriorated previously cut apart sections ofpipeline a length of reversible pipelining material which has anadhesive material which bonds a flexible liner section to the interiorsurface of the pipeline being repaired. This method requiresconsiderable excavation, pipeline cutting and reconnection thusincreasing pipeline downtime and the expense of repairing deterioratedpipeline.

[0005] There have also been methods known in the prior art which havecement mortar lining applied directly to the passageway or pipelinesurface by spraying, trowelling or other methods. The cement mortarlining may also be reinforced with metallic rods or the like. The cementmortar lining techniques are used in the prior art for large pipelinesand passageways where entry by a worker is possible and applying of suchmaterials therein is performed by the worker.

[0006] Still yet another method of applying liners to pipelines includesusing a flexible lining tube in conjunction with a felt or absorbentlayer or layers wherein the felt absorbent layers are impregnatedthoroughly with a curable synthetic resin at ground level and then animpregnated bag is fed into the pipe liners passageway before the resincures. This bag is then held to the surface by fluid pressure until theresin cures forming a rigid lining pipe inside the existing pipeline orpassageway.

[0007] There even have been prior art systems, known as cured in placepipe (CIPP), that use a scaffolding type set up to create a head ofwater at the repair site inside the pipeline which will be used toinvert the liner and activate a catalyst resin. The water is circulatedand heated through any known process but must be specifically controlledsuch that the proper temperature is delivered to the catalyst resinwhich is used to create the liner pipe inserted therein and the pipelinebeing repaired. Generally, there is no bond between the liner and thepipe and an annular space occurs between the two. One difficultyencountered with these prior art methods is that the catalyst must beapplied to the resin at a specific time after or at the same time theresin is inserted into the interior of the tube and before transferringthe tube to the repair site. Once the catalyst is applied to the resinthe resin begins curing and time is of the essence to properly locatethe liner tube in place within the pipeline to be repaired. Any problemsencountered will affect such timing and create liners that are notproperly cured or shaped to the interior surface of the pipe thusproviding for bulging or leaks which may allow water to seep between theliner placed within the pipe and the pipe itself.

[0008] It should also be noted that problems have been encountered inthe prior art methods with the cured in place pipe liners, when theresin is activated via a catalyst such as heat or any other catalystknown, the resin tends to shrink away from the interior surface of thepipe and thus creates many air pockets or portions of the liner that arenot directly adhered to the interior surface of the pipe. This reducesthe effectiveness and durability of the liner. This will also increasethe amount of repairs needed to the pipe after the liner is installedbecause of the water or any other seepage located between the lineroutside surface and the interior of the pipeline being repaired.

[0009] Problems have also been encountered with prior art methodsattempting to spray a liner onto the interior of a pipe being repaired.Many of these prior art spray systems would effectively just put anapparatus within the pipe and spray the liner directly onto the pipeafter much excavation or other preliminary work has occurred.Furthermore, the expense and downtime of such spray in liners hasadversely affected the choice to use such method in repairing problems.The spray in type liners have major problems with plugging of the spraytips used to apply such spraying to pipes or any other surfaces. Anytype of sprayed liner or sprayed resin tends to clog the tip of thespray gun at very fast rates thus slowing down the repair process andincreasing the cost by having to replace the head and or clean the headwhile also increasing the downtime of the pipe being repaired.Furthermore, problems have also been encountered with prior art spraylining methods wherein the spray coat does not cure quick enough andruns and sags occur away from the interior surface of the pipe or otherapparatus being repaired. In these prior art systems the spray coatingis applied to quickly with too much resin or coating being applied inthat quick manner. The resultant sprayed in lining is characterized byexcessive sags and runs which interferes with the flow of water or otherliquid through the pipe. Furthermore, the prior art spray liners thathave been used are very thin, 0.020 to 0.040 inch thick and aregenerally unacceptable for most applications.

[0010] Therefore, there is a need in the prior art for a sprayed inplace pipe liner apparatus and method. There also is a need in the artfor a sprayed in place pipe liner apparatus that overcomes the problemof the spray gun tip clogging and plugging at very short time intervals.

[0011] There also is a need in the art for a sprayed in place pipemethod and apparatus that will slow down the coating application rateand not spray too much coating too fast thus leading to sags, runs andair pockets being formed by the spray process.

[0012] There also is a need in the art for a low cost easy to applylining method and apparatus for fixing deteriorating pipelinesthroughout the infrastructures of cities without a lot of excavating orother above ground work. The non-excavation method is known as“trenchless technology”. There also is a need for a spray in liningmethod and apparatus to spray a coating that cures quickly and allowsfor shorter downtimes of the pipeline being repaired.

SUMMARY OF THE INVENTION

[0013] One object of the present invention is to provide an improvedsprayed in place pipe apparatus.

[0014] Another object of the present invention is to provide an improvedmethod of spraying a liner into a pipe in place.

[0015] Yet a further object of the present invention is to provide aspray in place pipe liner apparatus that has a clog free tip for use inspraying the liner for longer time intervals.

[0016] Still another object of the present invention is to provide asprayed in place pipe apparatus and method that will slow down thedelivery rate of the liner onto the interior surface of the pipe beingrehabilitated.

[0017] Still another object of the present invention is to provide a lowcost more reliable method of rehabilitating deteriorated pipe.

[0018] Still another object of the present invention is to provide aliner for deteriorating pipes that is capable of being applied in avariety of thicknesses over a variety of surfaces without extensive prepwork necessary for proper adhesion of the liner to the interior surfaceof the pipe.

[0019] Still another object of the present invention is to provide aneasy and quick to apply method of lining existing deteriorating pipeswith a potable material.

[0020] It is also an object of the present invention to provide asprayed in place apparatus that will move the spray head with relationto the robot thus achieving an over lapping pattern and lengthening thespray pattern by a predetermined factor.

[0021] Another object of the present invention is to provide a sprayedin place apparatus that will have an air blow off mechanism to force airat a very high rate through a spray tip while not effecting theuniformity of the coating within the pipe surface.

[0022] Another object of the present invention is to provide a methodnot requiring destruction of yards or landscapes and one that minimizesdisruption to neighborhoods as is usually required by CIPPS and theother lining techniques.

[0023] To achieve the fore going objects, a robotic apparatus forspraying a liner on the interior of a pipe structure is disclosed. Theapparatus will include a base having guide rails connected to a surfaceof the base. The apparatus will also include a shuttle plate arranged onthe guide rails. A gear mechanism will connect the shuttle plate andmove the shuttle plate along the guide rails a predetermined distance. Amotor will be secured to one end of the base and with a gear mechanismon the opposite end thereof. The apparatus will also include anextension arm secured to the shuttle plate. The apparatus will alsoinclude a spray head assembly connected to the extension arm which iscapable of axial movement relative to the base thus allowing for anoverlapping pattern to be sprayed on the interior surface of a pipestructure.

[0024] One advantage of the present invention is that it provides animproved sprayed in place pipe liner apparatus.

[0025] Still another advantage of the present invention is that itprovides for an improved method of spraying a liner in place indeteriorating pipeline structures.

[0026] Still another advantage of the present invention is that thesprayed in place pipe apparatus uses a robot with a spray head attachedthereto that moves with relation to the robot.

[0027] Still another advantage of the present invention is the abilityof the spray in place pipe liner apparatus to spray in an over lappingpattern thus reducing the speed of the coating process and ensuring amore uniform liner without runs or sags.

[0028] Yet another advantage of the present invention is that the sprayin place pipe liner apparatus includes a blow off mechanism attached tothe tip of a spray gun thus nearly eliminating any plugging of the spraytip during operation of the lining apparatus.

[0029] Still another advantage of the present invention is the abilityto rehabilitate deteriorated existing pipelines in a more cost effectiveand timely manner.

[0030] Yet another advantage of the present invention is the use of aquick cure coating such as a polyurea, polyurethane or combination torehabilitate the interior surface of deteriorating pipelines.

[0031] Yet another advantage of the present invention is the ability ofthe spray in place pipe liner to adhere to a variety of surfaces and/orgrooves or cavities found on the inside of a deteriorating pipe linestructure.

[0032] Yet another advantage of the present invention is the ability ofthe spray in place apparatus and method to operate for longer periods oftime thus reducing downtime of the pipe system being rehabilitated.

[0033] Still another advantage of the present invention is the abilityto apply a liner at a varying degree of thickness with a varying degreeof coating gel speeds.

[0034] Still another advantage of the present invention is the expulsionof the coating through the spray head onto a spinning disc which willdisperse the coating onto the inside surface of the pipe being lined ina uniform manner thus ensuring no runs, sags or air pockets between theexterior portion of the liner and the interior surface of the pipe beingrehabilitated.

[0035] Other objects, features and advantages of the present inventionwill become apparent from the subsequent description and the appendedclaims, taken in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0036]FIG. 1 shows a perspective view of the robotic base assemblyaccording to the present invention.

[0037]FIG. 2 shows a perspective view of the robotic base assemblyhaving the shuttle plate at the front end of a ball screw according tothe present invention.

[0038]FIG. 3 shows a top view of the base assembly of the roboticapparatus according to the present invention along with a top view ofthe extension arm and spray head assembly for use with the roboticapparatus according to the present invention.

[0039]FIG. 4 shows the robotic apparatus according to the presentinvention in the fully retracted position.

[0040]FIG. 5 shows the robotic apparatus according to the presentinvention in the fully extended position.

[0041]FIG. 6 shows a side view of the motor module in its upright 90°position according to the present invention.

[0042]FIG. 7 shows partial cross section of the robotic apparatusaccording to the present invention in a pipe being rehabilitated.

[0043]FIG. 8 shows a partial side view of the spinner disk, shaft, airmotor and splatter shield according to the present invention.

DESCRIPTION OF THE EMBODIMENT(S)

[0044] Referring to the drawings, a sprayed in place pipe linerapparatus 10 and method according to the present invention is shown. Thesprayed in place pipe liner apparatus 10 is for use in any known newpipeline or any known pipeline in need of rehabilitation. The sprayed inplace pipeline apparatus 10 is capable of being placed through existingman hole covers or placed through another cut in the pipe, such as butnot limited to those man made through excavating or the like. The sprayin place pipe liner apparatus 10 in one embodiment will be a robot thatis capable of having a camera mounted thereon and is capable of beingmoved through a pipe 12 and will disperse a fast cured coating onto theinterior of the pipe 12 being lined. It should be noted that the roboticapparatus 10 may not have a camera attached thereto. The roboticapparatus 10 will be moved through pipelines for rehabilitation onsliding rails 14 that have curved lead ends on one, neither or both endsthereof. The sliding rails 14 will allow the robot 10 to be movedthrough the pipe 12 at a predetermined speed thus allowing for a fastcure coating to be properly applied at predetermined thinknesses withinthe pipe environment. It should be noted that the robotic spray in placeapparatus 10 described herein is for use in rehabilitating pipelines ofexisting water and sewer systems but that any other type of structurehaving an interior surface maybe rehabilitated or lined with the roboticapparatus 10 or with a slightly modified apparatus that is capable ofapplying the fast cure coat in the shape of the surface beingrehabilitated. It should be noted that in the embodiment shown in thedrawings the robotic apparatus 10 will be capable of rehabilitatingpipes in size from 6″ in diameter to 48″ in diameter or larger.

[0045] The spray in place liner apparatus 10 is a robot that iselectronically controlled via a computer or other electronic workstationarrangement at a remote location during the rehabilitation process. Therobotic apparatus 10 generally has two main components, a base assembly16 and an extension arm 18.

[0046]FIGS. 1 and 2 show the base assembly 16. The base assembly 16generally has a rectangular shape. In one embodiment the base assembly16 is made of a steel material, however, it should be noted that anyother metal, hard ceramic, plastic, or composite etc. is also capable ofbeing used for the base assembly 16 depending on the environment and thedesign requirements. The base assembly 16 has a plurality of orificestherethrough for connecting other devices or apparatuses thereto. Afirst 20 and second guide rail 22 are connected to a top surface of thebase assembly 16. The first and second guide rails 20, 22 are generallycylindrical in shape and are parallel to another. The guide rails 20, 22are located along the outer edges of the base assembly 16. A guide railbracket 24 is located at each end of the guide rails 20, 22 or near eachend of the guide rails 20, 22 and each of the guide rail brackets 24 aresecured to the top surface of the base assembly 16. The guide rails 20,22 are then arranged within an orifice of the guide rail brackets 24 andsecured therein via fasteners or any other known method of securing aguide rail 20, 22 to a bracket 24. Each of the guide rails 20, 22 aremade of steel but it should be noted any other metal, plastic, ceramic,composite etc., may also be used.

[0047] A shuttle plate 26 having a generally square shape is slidinglyengaged with the first 20 and second guide rails 22 on the base assembly16. The shuttle plate 26 generally is made of a steel material however,it should be noted that any other metal, hard plastic, ceramic,composites or the like maybe used for the shuttle plate 26. The shuttleplate 26 includes a plurality of shuttle plate brackets 28 attached to abottom surface of the shuttle plate 26. The shuttle brackets 28 aregenerally located at or near each corner of the shuttle plate 26. Theshuttle plate brackets 28 are arranged along a common axis, such thattwo of the shuttle plate brackets 28 will be arranged around the firstguide rail 20 while the other two shuttle brackets 28 will be arrangedaround the second guide rail 22. This will allow the shuttle plate 26 tomove at in axial direction along the guide rails 20, 22 a predetermineddistance with respect to the base assembly 16. In one embodiment theshuttle plate 26 is capable of axial movement in approximately aneighteen inch axial range. However, it should be noted that any otherrange of axial movement from 1″ up to 48″ maybe used depending on thedesign of the base assembly 16 and the robotic apparatus 10 for thespray in place pipe liner. It should be noted that the shuttle plate 26includes a plurality of orifices 30 extending therethrough and extendingpartially therethrough for connecting the shuttle brackets 28 theretoand for connecting an extension arm 32 to the shuttle plate 26 on a topsurface thereof. The shuttle plate 26 also includes a cut out 34 at amid point of one side thereof for use in connecting a reverser nut 36thereto. The shuttle plate 26 is arranged on the first 20 and secondguide rail 22 such that the center point of the shuttle plate 26 willalign with a center point of the base assembly 16. It should be notedthat in one embodiment the shuttle plate 26 generally has a square shapebut that any other known shape maybe used such as a rectangular, circle,etc. depending on the design requirements for the robot apparatus 10. Itshould further be noted that the shuttle plate 26 as shown in FIGS. 1and 2 has a predetermined thickness but that any other thickness may beused depending on the strength needed and reliability needed of theshuttle plate 26.

[0048] A gear mechanism 38 is secured to a top surface of the baseassembly 16 along a centerline thereof and between the first 20 andsecond guide rails 22. The gear mechanism 38 in the present invention isa reserving ball screw 38. The reversing ball screw 38 generally has acylindrical shape with a threaded exterior surface. The ball screw 38will be supported on both ends by a ball screw bracket 40. The brackets40 will allow the ball screw 38 to be rotatably supported therein andallow for full rotate 360° rotation of the ball screw 38 within the ballscrew brackets 40. The ball screw brackets 40 will be secured to the topportion of the base assembly 16 through predetermined orifices by anyknown fasteners. The ball screw 38 will have a predetermined length andthread ratio. In the embodiment shown the ball screw 38 will allow theshuttle plate 26 to move in an approximate 18″ axial range along theguide rails 20, 22 of the base assembly 16. One end of the ball screwmechanism 38 will include a rotatable connector or bushing 42 attachedthereto. This bushing 42 will be attached to a compatible rotatableconnector or bushing 44 on one end thereof. The connector 44 will beattached to a motor 46 on the opposite end which will provide therotational torque necessary to rotate the ball screw 38 in both aclockwise and counter clock wise direction. The rotation of the bushing42 will rotate the ball screw 38 in either a clockwise or counter clockwise direction and in turn move the shuttle plate 26 along the guiderails 20, 22 in an axial direction with relation to the base assembly16. The reverser nut 36 will be arranged around the ball screw 38 priorto insertion of the ball screw 38 into the ball screw brackets 40 oneach end. The reverser nut 36 will then be secured via any knownfastener to the bottom surface of the shuttle plate 26 thus allowing theshuttle plate 26 to move in the axial direction during rotation of theball screw 38. The ball screw 38 will be rotated at a predeterminedangular velocity thus allowing for the shuttle plate 26 to move alongthe guide rails 20, 22 at a predetermined speed.

[0049] It should be noted that the gear mechanism 38 maybe somethingother than a ball screw but in one contemplated embodiment the ballscrew 38 is the most effective and reliable method of moving the shuttleplate 26 in the axial direction. However, it has been contemplated touse solenoids, a pulley and wire system, hydraulic cylinder etc. or thelike to move the shuttle plate 26 in a required axial direction alongthe base assembly 16. It should be noted that the ball screw 38 will becapable of moving the plate 26 a predetermined distance to the front endof the base assembly 16 and then stop or return automatically to therear end of the base assembly 16. This pattern of moving the shuttleplate 26 may continue on with any known type of repeating automaticpattern or in a pattern that has automatic delays built thereindepending on the requirements of the coating being sprayed on to theinterior surface of the pipeline.

[0050]FIGS. 1 and 2 also show the motor module 48 secured to one end ofthe base assembly 16. The motor module 48 generally includes a first 50and second arm member 52 arranged parallel to one another and eachconnected to a motor plate 54 on the opposite end thereof. The motorplate 54 has a plurality of orifices therein, including orifices thatallow for an air line to be attached, pneumatic cylinder air controlline to be attached and a first and second material line to be attachedfor making the fast cure coating. Hoses 56 are attached to the orifices.The hoses 56 are designed for specific applications. The material beingtransferred via the hoses 56 are passed through the motor plate 54 andthen transferred by other hoses 58 to the spray head 60 attached to theextension arm 18 of the robotic apparatus 10. It should be noted thatthe motor module arms 50, 52 are generally made of a steel materialalong with the motor plate 54 however any other know metal material,hard plastic, ceramic, composite or the like may also be used dependingon the design requirements. The first and second motor modules arms 50,52 generally have a predetermined sized oval orifice 62 or slot througha surface thereof. The orifice 62 is located adjacent to a predeterminedsized notch 64 on one end thereof. The orifice 62 and notch 64 willallow for the motor module 48 to be pivoted 90° vertically to allow forthe robotic apparatus 10 to be inserted into pipes 12 via different sizeman hole covers and different size entry points having a variety ofangled openings. The rotating of the motor module 48 is shown in FIG. 6with the motor module 48 in its vertical or 90° position. Any type offastener, dowel, or pin can be used as the pivot point 66 of the motormodule 48.

[0051] Arranged within the motor module arms 50, 52 and motor plate 54is a motor 46 for use in the robotic apparatus 10. In the embodimentshown a DC motor 46 is used to rotate the ball screw 38 and is capableof providing variable cycle speeds in the approximate range of 6 secondsto 16 seconds from the shuttle plate 26 leaving the retracted positionreaching the fully extended position and then returning to its retractedposition. It should be noted that any other time frame from 1 second toone minute maybe used depending on the speed required of the shuttleplate 26 in conjunction with the fast cured coat being applied. Itshould also be noted that any other type of motor such as all electricmotor, a solar motor, traditional fuel or alternative fuel motor,hydraulic motor or the like maybe used for the attached robot apparatus10. The motor 46 is fastened in the motor module 48 via any knownfasteners. The drive 68 of the motor 46 is connected to one end of therotatable bushing 44 while the opposite end of the bushing 44 isconnected to the bushing 42 connected to the ball screw 38, thusallowing for the rotational velocity to be passed from the motor 46 tothe ball screw mechanism 38. The motor 46 will be controlledelectrically via a computer or other electronic arrangement from aremote location on the surface or elsewhere in the pipeline environment.The electrical connections will be fed through a hose to the motor 46and attached thereto on one end while the opposite end is attached tothe control module, computer at the surface or other point of operation.It should be noted that it is contemplated to have the robotic apparatus10 connected with up to 600′ feet of cabling and hoses to allow forelectrical and material feeding to the robotic apparatus 10 during thespraying of the coating onto the interior surface of a pipe 12. Attachedto a front end of the motor module 48 arms is a lock plate 70 that whichwill lock the motor 46 in a predetermined position with relation to thebushings 42, 44 of the ball screw 38 and the drive 68 of the motor 46.The motor module 48 will be locked in place in the same vertical planewith the base assembly 16 during operation via any known fastener suchas screws, bolts or the like. The fasteners have to be removed for anypivoting of the motor module 48.

[0052] The slots 62 located on the end of the motor module arms 50, 52will have a locking feature that will require a predetermined distanceof sliding to occur before the slots 62 will lock and allow the motormodule 48 to rotate to it's 90° or other position with relation to thebase assembly 16. The feed hoses 58 which are attached to the motormodule and then onto the extension arm 18 will carry a variety ofmaterials such as a first and second material for creating the fast curecoating. Other of the hoses 58 will be used to carry pneumatic aircapable of providing the air necessary for the air motor 81 and blow offmechanism 77. Other hose bundles will be used to bring all electricalwires down to the motor 46 to control operation of the motor 46 andspray head 60 via electronic control from a trailer located at a remoteposition.

[0053]FIG. 3 shows the extension arm 18 and spray head assembly 60 foruse in the spray in place robotic apparatus 10. The extension arm 18includes a body 74 generally having a rectangular shape. It should benoted that the body 74 may be two L-shaped pieces abutting each other tocreate a “U” shaped cross section for the body 74. Attached to one endof the body 74 is a first and second extension arm base member and/orextension arm base member plate 76. These base members 76 will have aplurality of orifices therethrough and will be used to connected theextension arm 18 to the top surface of the shuttle plate 26 of the baseassembly 16. Located on the end of the body 74 opposite the base members76 is a spray head assembly 60. The extension arm 18 will include aplurality of feed hoses 78 carrying both the materials necessary to feedthe fast cure coating and the pneumatic lines necessary to create theblow off mechanism for the spray head assembly 60 and to operate thepneumatic cylinder 72 that actuates the spray head assembly 60. A tubeor conduit 73 is arranged between the cylinder 72 and spray head 60. Thetube 72 may have a rod arranged therein to act as a push pull rod and inaffect open or close the spray head 60 for its operations.

[0054] The hoses 78 will be looped such that the axial movement of theextension arm 18 relative to the base assembly 16 will allow the hoses78 to extend between the shuttle plate 26 fully extended and retractedpositions so there will be no kinks in the hoses 78 thus ensuring nopinching off of any supply of materials or air to the spray headassembly 60. The hoses 78 will be cradled in the channel formed by thebody 74 on the bottom of the extension arm 18 to keep them inside thevertical dimensions of the extension arm 18 thus not affecting the spraypattern of the fast cure coat. Each of the hoses 78 will have any wellknown connector on each end thereof and will be connected to any wellknown connector of the spray head assembly 60 or the motor 46 or to thetrailer where the materials will be stored for use in the roboticapparatus 10. A plurality of spray head nozzles and the like may beattached to the extension arm 48. All of these hose connections are wellknown in the art and may be any type of hose connection known in theart.

[0055] The extension arm base members 76 are connected to the topsurface of the shuttle plate 26 by any known fasteners such as a nut andbolt arrangement and/or any screw known in the art. It should also benoted that any other type or method of connecting two plates togethersuch as a weld or any other mechanical, chemical bonding means may alsobe used.

[0056] The spray head assembly 60 which is attached to the end of theextension arm 18 will include a spray gun that uses a spray gun tip 80that will combine the two major components of the coating at the tip ofthe gun and then expel the coating through the tip 80 at a predeterminedrate. The coating after being mixed will be expelled onto a spinningdisk 82 which will disperse the coating through centrifugal forces ontothe inside surface of the pipe 12 being lined. The spinning disk 82 willbe attached to one end of the spray head assembly 60 via a shaft 83arranged within an orifice 84. The spinning disk 82 will be controlledvia a pneumatic motor or electric motor and via air or electricitybrought from the trailer at the remote location. The spray head assembly60 will also include a splatter shield 86 located near or at the spraytip 80. The shield 86 may have a cone like shape or any known shape. Thesplatter shield 86 will prevent the coating from being blown back intothe spray tip 80 and contaminating the spray head assembly 60 duringoperation of the apparatus 10.

[0057] The disk 82 will be rotated at a predetermined speed and will usecentrifugal forces to annularly distribute the coating in a 360° arc. Inone embodiment the disk 82 will spin at approximately 10,000 to 12,000rpms however, it should be noted that any other rpm can be used suchas but not limited to 1,000rpms to 30, 000rpms depending on thedistribution required and the coating used, to ensure that no air istrapped within the coating thus creating air pockets or sagging in theliner being applied to the interior of the pipe 12. The distribution ofthe coating via the centrifugal force, when the coating is expelled intothe spinning disk 82 will ensure no air is trapped in the coating and aneven distribution of the coating throughout the entire pipe surface.This even distribution also includes any cavity or the like in thesurface of the pipe thus allowing for a complete new liner matching theinterior surface of the previously laid pipe. The extension arm 18 iscapable of having more than one spray head spray tip 80 attached to thespray head assembly 60. This will allow for multiple coatings to beapplied at the same time, but curing at different rates thus allowingfor a first coating to be applied and cured and then a second coating tobe applied directly thereafter. It should be noted that the spray headassembly 60 generally is made of a steel material but that any othertype of metal, ceramic, hard plastic, composite or the like material maybe used for the spray head assembly 60. The spray tip 80 and spray gunsare any of the well known spray tips 80 and guns used in the spraycoating. The spray tip 80 is arranged such that an air blow offmechanism 77, capable of applying high velocity high pressure airthrough the tip 80, is arranged on the extension arm 18. This blow offair mechanism 77 will force high velocity air around the tip 80 at thesame time as the mixed coating materials are sent through the tip 80.This will create a fine spray of the coating which will be expelled ontothe spinning disk 82 and then through centrifugal forces dispersed ontothe interior surface of the pipeline being lined.

[0058]FIGS. 4 and 5 show the robotic apparatus 10 with the extension arm18 connected to the base assembly 16. The extension arm 18 in FIG. 4 isin its fully retracted position prior to start up of the liningmethodology. The robotic apparatus 10 as shown in FIG. 5 shows theextension arm 18 in the fully extended position at the far end of thebase assembly 16 on the guide rails 20, 22. The methodology will havethe shuttle plate 26 moving between the positions shown in FIGS. 4 and 5in a continuous loop, thus allowing for an overlapping spray pattern tobe applied to the interior surface of the pipe 12. FIGS. 4 and 5 showthe extension arm 18 connected to the top of the shuttle plate 26.

[0059]FIG. 7 shows a cross section of a section of pipe to berehabilitated via the robotic apparatus 10 and methodology of thepresent invention. FIG. 7 shows a pipe 12 from a existing sewer systemor the like that needs rehabilitation. The robotic apparatus 16including the base assembly 16, extension arm 18 and spray head assembly60 will be inserted into the pipe 12 and on top of sliding rails 14 thatmay have curved lead ends on both ends thereof. The slide rails 14 maybeof any type known but are compatible with the base assembly 16 and willallow the base assembly 16 to slide at predetermined speeds through thepipeline environment. The robotic apparatus 10 will be placed on top ofthe sliding rails 14 and will be pulled forward into starting positionby a detachable cable and winch system 87. The cable and winch system 87will be fed backwards through the pipe 12 from the next manhole or entrypoint in the pipeline system. Once the robotic apparatus 10 is in properstarting position the cable will be unhooked and withdrawn from thepipeline system the robot 10 will then be pulled backwards in thedirection from which it entered during the spray sequence by the hoseassembly 90 which is attached to the motor module 48 on one end thereof.The hose assembly 90 will include all material for the fast cure coatingand all electrical and pneumatic lines necessary to operate the roboticapparatus 10 as discussed above. The hose assembly 90 in one embodimentwill be reinforced in tension by any known reinforcement method such asbut not limited to an air craft cable integrated with the cable bundleto allow for tension strength and the ability to pull such cable bundleswithout kinking or adversely effecting the material feed lines, the airand the electrical lines.

[0060] The robotic apparatus 10 will be pulled at a predetermined speedthrough the pipe line such that it will permit application of thecoating in very thin to very thick applications with a high degree ofuniformity throughout the thickness and excellent surface adhesion tothe interior of the pipe and excellent surface smoothness on theinterior surface of the liner. It is contemplated that the thicknessesof the coatings can vary from anywhere from {fraction (1/18)}″ to 1″ butother thicknesses are also contemplated depending on the interiors ofthe pipes being fixed. The robotic apparatus 10 will be moved at thepredetermined speed that will permit the use of very fast curing systemsand much slower curing systems depending on the design environment andtype of lining to be inserted. Thus, the system is capable of allowingthe use of faster cure coatings that will gel within approximately 4seconds to slow fast cure coating systems that will gel any where from20-40 seconds after application. It should be noted that the roboticsystem is also capable of being used to apply multiple coats of theliner thus releasing any trapped air efficiently from the sprayed inplace liner.

[0061] The methodology of applying the liner to the interior surface ofthe pipeline being rehabilitated takes advantage of the movement of therobot 10 through the pipe at a predetermined speed along with themovement of the spray head 60 relative to the movement of the robot baseassembly 16. Thus, the spray head 60 will be oscillating with respect tothe base assembly 16 of the robotic apparatus 10 during the spraying ofthe fast cure coating. It should be noted that the fast cure coatingused in the present invention is a polyurea coating sold under theWarrior and Structr Spray™ by Visuron Systems, Inc of Bay City, Mich. Inprior art systems too much coating was applied too fast thus causingruns and sags in the liners being applied to the interior surfaces ofpipeline systems. The current oscillation method will lengthen the spraypattern by up to 12 times. This lengthening of the spray pattern willallow for multiple passes for predetermined areas of the interiorsurfaces of the pipe. By lengthening the spray pattern up to 12 times,very thin to very thick coatings maybe applied with one pass of therobotic apparatus 10 through the pipeline system. Prior art systemswould have to have a minimum of 8 passes to provide for a ⅛ thickness onthe interior of the pipes. Even then too much coating was being appliedtoo fast thus allowing for runs and sags to form in the walls thusforming air pockets between the liners and the interior surface of thepipe being rehabilitated. The longer spray patterns performed byoscillating the head 60 with respect to the robot base assembly 16,which is also moving at a predetermined speed, will eliminate runs andsags and will allow for any glitches within the pipeline environment tobe covered via multiple passes. Thus, the oscillation part of themethodology solves the prior art problems of applying too much coatingtoo fast thus eliminating any runs or sags and uneven distribution ofthe coating within the pipeline environment. This movement of the sprayhead 60 with relation to the robot base assembly 16 and over allmovement of the robot apparatus 10 will achieve an over lapping patternthus allowing multiple coats to be applied in a shorter time frame andeffectively slowing down delivery of the coating to the pipe 12 beinglined thus reducing the number of runs and sags while also increasingthe adhesion of the sprayed in pipe liner to the pipe 12.

[0062] The methodology also will use an air blow off mechanism 72 thatwill deliver high velocity air to ensure clogging of the spray tip 80does not occur during the up to one hour or more lining process. It hasbeen shown in the prior art that when spraying fast gel systems, whichgenerally are all systems that gel under 60 seconds, a build up wouldtend to accumulate at the tip of a spray gun in a minute or so such thatthe spray pattern becomes highly distorted. This build up will rapidlybecome so large that it could plug off the flow of the coating from thespray tip. The pipe lining methodology and apparatuses discussed hereinrequire a single continuous uninterrupted spray sequence of one hour ofmore in most applications. Hence, increasing the airflow will enhancethe performance of the spray tip 80. However, it also must be balancedby having badly distorted spray patterns because entrained air which istrapped in the coating may cause trapped air voids in the liner to beapplied to the interior surface of the pipe. Therefore, instead ofkeeping the low air flow to keep the coating in its proper density thepresent invention methodology will use an air flow rate that is muchhigher then that used in regular spraying. Thus, a very high air flowrate will be used to keep the spray tip 80 clean for the extended timeperiod necessary for the pipe lining methodology. The much higherairflow will not interfere with the spray pattern because the distortionwill have no effect due to the coating being disbursed onto the spinningdisk 82 as described above. The extremely fine spray that will exit thespray tip due to the high air flow from the air blow off mechanism willefficiently displace any entrained air because of the velocity of thesolids and density difference of the two materials as it impacts theinterior pipe surface. Therefore, the air blow off mechanism will forcehigh speed air at predetermined pressures through the spray tip 80allowing for the spray tip to remain clean during the one hour or sooperation of the spray in place lining apparatus.

[0063] The pipe lining apparatus 10 is capable of working in 300 to 600′sections of pipe at a time. Thus, an hour or more maybe necessary forthe robot apparatus 10 to be applying the spray coating within therehabilitated pipe. It should be noted that any other type of fast curecoating other than polyurea maybe used but polyurea is the preferredcoating to be used because of its fast gel properties and potablecharacteristics.

[0064] This methodology and apparatus will allow for more costefficient, more reliable and more durable pipe linings for deterioratedpipelines that need rehabilitation. The methodology will be capable ofoperating in 300′ to 600′ intervals and completing such a section withinan hour to two hour worth of man hours. This will have less downtime forthe pipe system being rehabilitated and more efficiently and costeffectively allow for pipes to be rehabilitated to near new. With thefast cure coatings forming to any irregularity on the interior of thepipe there is less chance of any air pockets forming thus therehabilitated pipe will last much longer then any insitu method and evenlonger than replacing the pipes by excavating and replacement or otherhigh cost methods.

[0065] It should be noted that a trailer will be the operation centerfor the methodology and apparatus and will be located adjacent to a manhole cover where the rehabilitation of the pipe is being worked. Thetrailer will house all electronic apparatus, all pneumatic apparatus andthe materials necessary to create the fast cure coating within thetrailer. Thus, the rehabilitation can occur during any weatherconditions, thus increasing efficiency and decreasing downtime of thepipeline system being rehabilitated. It should be noted that the systemwill operate such that one half gallon to one gallon of coating will besprayed per minute during prime and efficient operation of the apparatusand methodology involved. The polyurea is a dual component system thatuses an A material and a B material and is approximately delivered at2500 psi and will cure within 4 to 5 second tack free from itsapplication to the inside surface of the pipeline process. Thus, therehabilitated pipes will be capable of operation within a matter ofhours from the coating being applied thereto.

[0066] The present invention has been described in an illustrativemanner. It is to be understood that the terminology, which has beenused, is intended to be in the nature of words of description ratherthan of limitation.

[0067] Many modifications and variations of the present invention arepossible in light of the above teachings. Therefore, within the scope ofthe appended claims, the present invention maybe practiced otherwisethan as specifically described.

What is claimed is:
 1. An apparatus for spraying a liner on the interiorof a structure, said apparatus including: a base; a guide rail connectedto a surface of said base; a shuttle plate arranged on said guide rail;a gear mechanism contacting said shuttle plate; a motor attached at oneend of said base; an extension arm secured to said shuttle plate; and aspray head assembly connected to said extension arm.
 2. The apparatus ofclaim 1 wherein said guide rail including a first and second cylindricalrod.
 3. The apparatus of claim 1 wherein said shuttle plate slides alongsaid guide rail a predetermined length of said base.
 4. The apparatus ofclaim 3 wherein said predetermined length is approximately between tenand twenty four inches.
 5. The apparatus of claim 1 wherein said gearmechanism includes a ball screw.
 6. The apparatus of claim 5 whereinsaid ball screw moves said plate in one direction and then automaticallyreverses direction.
 7. The apparatus of claim 1 wherein said motor issecured to a coupling, said coupling connected to said base.
 8. Theapparatus of claim 7 wherein said coupling having at least one slottherein.
 9. The apparatus of claim 8 wherein said coupling pivots in a90° arc with relation to said base.
 10. The apparatus of claim 1 whereinsaid extension arm is secured to said shuttle plate on one end thereof,said spray head assembly secured to an opposite end of said extensionarm.
 11. The apparatus of claim 1 wherein said spray head assemblyhaving a disk arranged within an orifice of said spray head assembly.12. The apparatus of claim 1 wherein said spray head assembly having asplatter shield.
 13. The apparatus of claim 1 further including aplurality of hoses connected to said spray head assembly and said motor.14. The apparatus of claim 11 wherein said spray head assembly willspray a liner at a predetermined flow rate in conjunction with an airblow off mechanism and said disk.
 15. The apparatus of claim 14 whereinsaid spray head assembly will oscillate with respect to said base, saidbase moving at a predetermined speed with respect to the structure. 16.The apparatus of claim 1 further including a rail system on an interiorsurface of the structure.
 17. The apparatus of claim 16 wherein saidbase moves in a predetermined direction on said rail system.
 18. Theapparatus of claim 1 further including a remote operation unit connectedto said coupling via a bundle, said remote unit electrically incommunication with the apparatus.
 19. The apparatus of claim 11 whereinsaid disk being mounted at 90° to an attaching shaft.
 20. The apparatusof claim 11 wherein said disk being mounted at up to a 20° oblique anglewith rotation to an attaching shaft, so as to dispense a wider spraypattern from said disk.
 21. A method of spraying a liner on an insidesurface of a structure, said method including the steps of: inserting anapparatus within the structure; moving said apparatus a predeterminedspeed through the structure; spraying a predetermined material from aspray head secured to said apparatus; and oscillating said spray headwith relation to said apparatus to form an over lapping pattern on theinside surface of the structure.
 22. The method of claim 21 wherein saidstep of oscillating includes a linear movement of said spray head alonga longitudinal axis of said apparatus.
 23. The method of claim 22wherein said linear movement is a predetermined distance within therange of five inches to 36 inches.
 24. The method of claim 21 whereinsaid oscillating step allows for application thickness of approximately0.060 inches to 20 inches in an even 360° arc pattern.
 25. The method ofclaim 21 wherein said oscillating allows fast to slow gelling of saidpredetermined materials in the range of approximately 3 sec. to gel to45 sec. to gel.
 26. The method of claim 21 further including the stepsof blowing air through a nozzle of said spray head at a high flow rate.27. The method of claim 26 wherein said air flow creates a fine sprayhaving and predetermined material dispersed therein.
 28. The method ofclaim 27 further including the step of propelling said fine spray into aspinning disk.
 29. The method of claim 28 wherein said disk spinsbetween approximately 2,500 to 15,000 r.p.m. and disperses said materialon the inside surface of the structure by centrifugal force.
 30. Themethod of claim 29 wherein said fine spray disperses any trapped airbecause of the high velocity thereof and density of said material. 31.The method of claim 21 wherein said predetermined material is polyurea.